Methods and Systems for Removing Material from Bitumen-Containing Solvent

Abstract

Methods and systems for preparing bitumen-laden solvent for downstream processing are described. The bitumen-laden solvent can be treated with various materials, such as water and emulsion breakers, followed by treating the bitumen-laden solvent in a desalter. The desalted bitumen-laden solvent can then be subjected to downstream processing, such as upgrading in a nozzle reactor.

Description

This application claims priority to U.S. Provisional Application No. 61/579,948, filed Dec. 23, 2011, the entirety of which is hereby incorporated by reference.

BACKGROUND

Extraction of bitumen from bituminous material such as oil sands can be carried out using a variety of different processes. Many extraction processes use solvent capable of dissolving bitumen as a means for extracting bitumen from bituminous material. As a result, an initial product of many extraction processes is a bitumen-containing solvent stream. Bitumen-containing solvent streams generally include solvent having a content of bitumen dissolved therein.

Many bitumen-containing solvent streams also include other components in the solvent stream. For example, many bitumen-containing solvent streams will include non-bitumen solid particles. The non-bitumen solid particles can include a variety of different materials, including inorganic salts, silica, and coal particles. These solid particles are often present in the bitumen-containing solvent streams because they are present in the material from which the bitumen-containing solvent was obtained. For example, when the bituminous material is oil sands, the oil sands material will generally include inorganic salts and silica. In that event, the solvent used to extract bitumen from the oil sands will also usually pick up a portion of these solid particles.

Generally speaking, the presence of this solid material in the bitumen-containing solvent is undesirable. A primary reason why the solid material is undesirable is that the solid material can cause a variety of issues in downstream processing of the bitumen-containing solvent material. For example, when the bitumen-containing solvent material is run through heat exchangers prior to being separated in a distillation column, the solid material can leave deposits on and foul the heat exchangers. Also, when bitumen-containing solvent is heated prior to distillation, some solid materials can be converted to corrosive material.

For example, inorganic salts present in bitumen-containing solvent, such as magnesium chloride, can convert to hydrochloric acid when exposed to elevated temperatures. The hydrochloric acid can subsequently damage downstream processing equipment, such as overhead condensers used after distillation. In another example, solid materials in bitumen-containing solvent upgraded in a nozzle reactor can act as coke precursors that can eventually plug the nozzle reactor.

Various attempts have been made to remove solid material from bitumen-containing solvent streams prior to downstream processing. For example, both filtration systems and centrifuges have been used to treat bitumen-containing solvent with the aim of removing non-bitumen solid material. One of the biggest problems faced with both filtration systems and centrifuges is the difficulties with scaling up this equipment when large volumes of bitumen-containing solvent need to be treated. In both instances, scale up of this equipment can be commercially unfeasible. Additionally, with respect to centrifuges, the separation of solids usually provides less than desirable results, and the separation typically has to occur on a batch basis rather than on a more desirable continuous basis.

SUMMARY

The applicants have invented an improved method and system for removing material, such as solid particles, from a stream of bitumen-containing solvent. In some embodiments, the method can include the steps of: i) providing a bitumen-containing solvent stream; ii) mixing the bitumen-containing solvent stream and a water stream; iii) introducing the mixture of the bitumen-containing solvent stream and the water stream in to a desalter, such as to remove, for example, solid particles from the mixture; iv) removing a desalted bitumen-containing solvent stream from the desalter; and iv) subjecting the desalted bitumen-containing solvent stream to downstream processing. In some embodiments, the downstream processing includes injecting the desalted bitumen-containing solvent stream into a nozzle reactor in order to upgrade the bitumen component of the desalted bitumen-containing solvent stream.

In certain embodiments, a system for removing solids from a stream of bitumen-containing solvent and upgrading the bitumen component of the resulting stream can include a) a desalter having a bitumen-containing solvent stream inlet and a desalted bitumen-containing solvent stream outlet, and b) a nozzle reactor having a feed material inlet that is in fluid communication with the desalted bitumen-containing solvent stream outlet of the desalter. In some embodiments, the system can also include a mixing vessel upstream of the desalter for mixing water and a bitumen-containing solvent stream.

Various advantages can be achieved from the methods and systems described herein. For example, in some embodiments, the methods and systems can provide for improved separation of solid particles, including inorganic salts and other undesirable solid material such as silica and coal particles, from bitumen-containing solvent streams. In certain embodiments, the methods and systems can be performed/operated continuously, and it can be commercially feasible to scale up the desalter used in the methods and systems so that the methods and systems can continuously process large volumes of bitumen-containing solvent.

It is to be understood that this Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. As a result, this Summary, and the foregoing Background, are not intended to identify key aspects or essential aspects of the claimed subject matter.

In addition, these and other aspects of the presently described methods and systems will be apparent after consideration of the Detailed Description and accompanying Figures. It is to be understood, however, that the scope of the systems and methods described herein shall be determined by the claims as issued and not by whether given subject matter addresses any or all issues noted in the Background or includes any features or aspects recited in this Summary.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the presently described systems and methods, including the preferred embodiments, are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.

FIG. 1 is a flow chart detailing steps of a method of separating non-bitumen solid particles from a bitumen-containing solvent stream according to various embodiments described herein;

FIG. 2 is a cross-sectional view of a desalter suitable for use in various embodiments described herein;

FIG. 3 is a block diagram illustrating a system suitable for use in carrying out some of the methods disclosed in this specification;

FIG. 4 shows a cross-sectional view of some embodiments of a nozzle reactor suitable for use in various embodiments of the systems and methods described herein;

FIG. 5 shows a cross-sectional view of the top portion of the nozzle reactor shown in FIG. 4;

FIG. 6 shows a cross-sectional perspective view of the mixing chamber in the nozzle reactor shown in FIG. 4;

FIG. 7 shows a cross-sectional perspective view of the distributor from the nozzle reactor shown in FIG. 4;

FIG. 8 shows a cross-sectional view of some embodiments of a nozzle reactor suitable for use in various embodiments of the systems and methods described herein; and

FIG. 9 shows a cross-sectional view of the top portion of the nozzle reactor shown in FIG. 7.

DETAILED DESCRIPTION

With reference to FIG. 1, a method 1000 for removing solid particles from a bitumen-containing solvent stream includes a step 1100 of mixing a bitumen-containing solvent stream with a water stream, a step 1200 of introducing the mixture of bitumen-containing solvent and water into a desalter, a step 1300 of removing a desalted bitumen-containing solvent stream from the desalter, and a step 1400 of subjecting the desalted bitumen-containing solvent stream to downstream processing. The removal of the solid particles in the desalter reduces or eliminates several issues that can arise when downstream processing is carried out on bitumen-containing solvent streams including solid material such as inorganic salts and silica.

In step 1100, a bitumen-containing solvent stream is mixed with a water stream. One objective of mixing the water stream and the bitumen-containing solvent stream is to provide water in which the solid particles can become immersed and/or dissolve. In this manner, the solid particles leave the bitumen-containing solvent stream and become a part of the water in the mixture. Due to the immiscible nature of the bitumen-containing solvent and the water, this then provides a mechanism for separating the solids from the bitumen-containing solvent stream by removing the water from the mixture of bitumen-containing solvent and the water.

The bitumen-containing solvent can include a solvent in which bitumen content is dissolved. In some embodiments, the bitumen-containing solvent includes from 0 to 35% solvent and from 100 to 65% bitumen. In some embodiments, the bitumen-containing solvent also includes from 0.001 to 1% non-bitumen solid material.

Many different types of non-bitumen solid material can be present in the bitumen-containing solvent. Examples include, but are not limited to, inorganic salts (such as magnesium chloride, calcium chloride, and sodium chloride), silica, catalyst fines, quartz, rust, silt, metals, metal oxides, and coal particles. In some embodiments, the amount of non-bitumen solid material in the bitumen-containing solvent stream can range from 0.01 to 1%. The bitumen-containing solvent may also include water, such as from 0.01 to 2% water.

The solvent component of the bitumen-containing solvent can be any solvent capable of dissolving bitumen. The solvent component typically includes the type of solvent traditionally used in solvent bitumen extraction techniques.

In some embodiments, the solvent is an aromatic solvent, such as Solvesso 100 or Solvesso 150 (commercially available solvents manufactured by ExxonMobil Chemical). In some embodiments, the solvent is a paraffinic solvent, such as propane, butane, pentane, hexane, heptanes, or mixtures thereof. In some embodiments, the solvent is a polar solvent, such as methanol. The solvent can also include two or more different solvents, such as any combination of the solvents listed above.

The bitumen-containing solvent can be obtained from any suitable source. In some embodiments, the bitumen-containing solvent is obtained from a bitumen extraction process that results in the production of a bitumen-containing solvent. In some embodiments, this generally includes solvent bitumen extraction processes that use a solvent as part of the bitumen extraction mechanism.

In some embodiments, the bitumen extraction process from which the bitumen-containing solvent is obtained is a single solvent bitumen extraction process, such as those described in U.S. patent application Ser. Nos. 13/558,041; 13/557,503; 13/557,842; 13/559,124; and 13/584,432 each of which is hereby incorporated by reference in its entirety.

In some embodiments, the bitumen extraction process from which the bitumen-containing solvent stream is obtained is a double solvent bitumen extraction process, such as those processes described in U.S. Pat. Nos. 7,909,989; 7,985,333; 8,101,067; 8,257,580; U.S. Published Application Nos. 2011/0062057; 2011/0155648; 2011/0180458; 2011/0180459; 2012/0152809; and 2012/0228196, each of which such Patent and Application as applicable is hereby incorporated by reference in its entirety.

In some embodiments, the bitumen extraction process from which the bitumen-containing solvent stream is obtained is an in-situ solvent extraction process, such as those processes described in U.S. patent application Ser. Nos. 13/584,333 and 13/557,842, each of which such Application is hereby incorporated by reference in its entirety.

In some embodiments, the bitumen extraction process from which the bitumen-containing solvent stream is obtained is a Steam Assisted Gravity Drainage (SAGD) process, in which steam is injected into deposits of bituminous material to decrease the viscosity of the bitumen and allow it to flow out of the deposit via production wells. The product of the SAGD process may be a mixture of water and bitumen material. In some embodiments, solvents are used in conjunction with the steam to help extract the bitumen from the bituminous deposits and/or are added to the recovered SAGD product. In such embodiments, SAGD processes provide a bitumen-containing solvent stream.

The water stream used in step 1100 for mixing with bitumen-containing solvent stream can be any suitable water stream available. In some embodiments, the water is of a water wash quality. A suitable water source includes, but is not limited to, stripped sour water provided that ammonia and hardness levels are kept low and the pH is kept high to keep salts from partitioning the oil phase.

The mixing of the bitumen-containing solvent and water can be carried out in any suitable fashion. In some embodiments, the mixing of the bitumen-containing solvent and water occurs in a mixing vessel.

Any vessel capable of receiving a water stream and a bitumen-containing solvent stream and mixing the two can be used. In some embodiments, the mixing vessel is piping through which the bitumen-containing solvent stream and/or water is transported. For example, the mixing can take place at a mixing valve where water travelling through pipelines joins the bitumen-containing solvent travelling through pipelines.

When a mixing vessel is used, the mixing vessel can include a water inlet, a bitumen-containing solvent inlet, and a bitumen-containing solvent outlet through which the mixture of water and bitumen-containing solvent can leave the mixing vessel. In some embodiments, the bitumen-containing solvent outlet of the mixing vessel is in fluid communication with a bitumen-containing solvent inlet of a downstream desalter so that the mixture of water and bitumen-containing solvent leaving the mixing vessel can be introduced into the desalter for removal of solid material from the mixture.

The mixing of the two streams is preferably vigorous mixing such that the mixing promotes the movement of solid particles in the bitumen-containing solvent into the water. Any suitable equipment and/or technique can be used to promote vigorous mixing between the two streams. In some embodiments, the amount of water mixed with bitumen-containing solvent stream is from 4 to 25% by volume of the bitumen-containing solvent stream.

Additional steps can be performed before, after, or as part of the mixing step 1100. For example, in some embodiments, the bitumen-containing solvent can be heated prior to being mixed with the water in step 1100. Any manner of heating the bitumen-containing solvent can be used, and in some embodiments, the bitumen-containing solvent is heated to a temperature of from 70 to 120° C. In some embodiments, the resulting mixture of water and bitumen-containing solvent is heated to a temperature of from 80 to 110° C.

In some embodiments, an emulsion breaker is added to the bitumen-containing solvent phase prior to mixing or after the mixing of bitumen-containing solvent and water. Any suitable emulsion breaker can be used, including but not limited to water soluble or oil soluble demulsifying agents such as amines, amyl resins, butyl resins or nonyl resins. The emulsion breaker can help to promote the separation of the bitumen-containing solvent and the water in the desalter.

In step 1200, the mixture of water and bitumen-containing solvent is introduced into a desalter. The desalter works to remove non-bitumen solid particles from the bitumen-containing solvent, including both inorganic salts and other materials such as silica and coal particles. Any suitable desalter can be used for carrying out the separation of solid particles from the bitumen-containing solvent.

With reference to FIG. 2, a cross-section view of an exemplary desalter suitable for use in the method described herein is illustrated. As shown in FIG. 2, a mixture of water and bitumen-containing solvent enters the desalter as an immiscible mixture of water droplets suspended in the bitumen-containing solvent. The vigorous mixing of the water and bitumen-containing solvent prior to introduction of the mixture into the desalter results in solid particles from the bitumen-containing solvent now being immersed and/or dissolved in the water droplets. A positive and negative electrode are provided proximate the entry of the mixture into the fluid tank of the desalter in order to create an electrostatic field that induces dipole attractive forces between neighboring droplets of water. In other words, the electrostatic field results in each droplet having a positive charge on one side and a negative charge on the other. The attractive force generated by the opposite charges on neighboring water droplets causes the water droplets to coalesce. The resulting larger water globules, along with solids, then settle to the bottom of the fluid tank. The settled water is continuously withdrawn from the desalter from a point somewhat above the desalter bottom.

In step 1300, a desalted bitumen-containing solvent stream is removed from the desalter. As shown in FIG. 2, the desalted bitumen-containing solvent is removed from an outlet at the top of the desalter. The outlet at the top of the desalter takes advantage of the desalted bitumen-containing solvent resting on top of the settled water phase and helps to ensure that predominantly or only desalted bitumen-containing solvent exits the outlet at the top of the desalter. As shown in FIG. 2, a baffle can also be positioned inside of the desalter to further ensure that no water droplets or globules end up exiting the desalter via the outlet of the desalted bitumen-containing solvent phase.

Once the desalted bitumen-containing solvent stream is removed from the desalter, step 1400 of performing downstream processing on the bitumen-containing solvent stream can be performed with little or no concern over the downstream processing being negatively impacted by solid particles contained within the bitumen-containing solvent stream.

Downstream processing of the desalted bitumen-containing solvent stream is not limited and may include any processing steps known and used by those of ordinary skill in the art. In some embodiments for example, downstream processing can include passing the desalted bitumen-containing solvent stream through a heat exchanger in order to warm the stream. The removal of solid particles from the stream allows for the use of a heat exchanger with reduced or eliminated concerns pertaining to fouling the heat exchanger due to solid deposits forming on the walls of the heat exchanger.

In some embodiments, the downstream processing includes use of a distillation tower to separate solvent from bitumen and/or separate fractions of the bitumen component. Atmospheric and/or vacuum distillation towers can be used. The removal of the solid particles from the bitumen-containing solvent stream can be performed prior to the distillation so that material capable of converting to corrosive material (i.e., magnesium chloride capable of converting to HCl due to water hydrolysis) is not present in the distillation towers and associated condensers.

In some embodiments, the downstream processing includes the cracking and upgrading of the bitumen component of bitumen-containing solvent. Cracking and upgrading can be carried out in, for example, a nozzle reactor. In some embodiments, the desalted bitumen-containing solvent provided by the desalter is injected into a nozzle reactor similar or identical to the nozzle reactor described in U.S. Pat. No. 7,618,597; U.S. Pat. No. 7,927,565; U.S. Published Application No. 2011/0084000; and U.S. Published Application No. 2011/0308995, each of which is hereby incorporated by reference in its entirety.

FIGS. 4 and 5 show cross-sectional views of one embodiment of a nozzle reactor 100 suitable for use in the methods described herein. The nozzle reactor 100 includes a head portion 102 coupled to a body portion 104. A main passage 106 extends through both the head portion 102 and the body portion 104. The head and body portions 102, 104 are coupled together so that the central axes of the main passage 106 in each portion 102, 104 are coaxial so that the main passage 106 extends straight through the nozzle reactor 100.

It should be noted that for purposes of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

The nozzle reactor 100 includes a feed passage 108 that is in fluid communication with the main passage 106. The feed passage 108 intersects the main passage 106 at a location between the portions 102, 104. The main passage 106 includes an entry opening 110 at the top of the head portion 102 and an exit opening 112 at the bottom of the body portion 104. The feed passage 108 also includes an entry opening 114 on the side of the body portion 104 and an exit opening 116 that is located where the feed passage 108 meets the main passage 106.

During operation, the nozzle reactor 100 includes a reacting fluid that flows through the main passage 106. The reacting fluid enters through the entry opening 110, travels the length of the main passage 106, and exits the nozzle reactor 100 out of the exit opening 112. A feed material flows through the feed passage 108. The feed material enters through the entry opening 114, travels through the feed passage 106, and exits into the main passage 108 at exit opening 116.

The main passage 106 is shaped to accelerate the reacting fluid. The main passage 106 may have any suitable geometry that is capable of doing this. As shown in FIGS. 4 and 5, the main passage 106 includes a first region having a convergent section 120 (also referred to herein as a contraction section), a throat 122, and a divergent section 124 (also referred to herein as an expansion section). The first region is in the head portion 102 of the nozzle reactor 100.

The convergent section 120 is where the main passage 106 narrows from a wide diameter to a smaller diameter, and the divergent section 124 is where the main passage 106 expands from a smaller diameter to a larger diameter. The throat 122 is the narrowest point of the main passage 106 between the convergent section 120 and the divergent section 124. When viewed from the side, the main passage 106 appears to be pinched in the middle, making a carefully balanced, asymmetric hourglass-like shape. This configuration is commonly referred to as a convergent-divergent nozzle or “con-di nozzle”.

The convergent section of the main passage 106 accelerates subsonic fluids since the mass flow rate is constant and the material must accelerate to pass through the smaller opening. The flow will reach sonic velocity or Mach 1 at the throat 122 provided that the pressure ratio is high enough. In this situation, the main passage 106 is said to be in a choked flow condition.

Increasing the pressure ratio further does not increase the Mach number at the throat 122 beyond unity. However, the flow downstream from the throat 122 is free to expand and can reach supersonic velocities. It should be noted that Mach 1 can be a very high speed for a hot fluid since the speed of sound varies as the square root of absolute temperature. Thus the speed reached at the throat 122 can be far higher than the speed of sound at sea level.

The divergent section 124 of the main passage 106 slows subsonic fluids, but accelerates sonic or supersonic fluids. A convergent-divergent geometry can therefore accelerate fluids in a choked flow condition to supersonic speeds. The convergent-divergent geometry can be used to accelerate the hot, pressurized reacting fluid to supersonic speeds, and upon expansion, to shape the exhaust flow so that the heat energy propelling the flow is maximally converted into kinetic energy.

The flow rate of the reacting fluid through the convergent-divergent nozzle is isentropic (fluid entropy is nearly constant). At subsonic flow the fluid is compressible so that sound, a small pressure wave, can propagate through it. At the throat 122, where the cross sectional area is a minimum, the fluid velocity locally becomes sonic (Mach number=1.0). As the cross sectional area increases the gas begins to expand and the gas flow increases to supersonic velocities where a sound wave cannot propagate backwards through the fluid as viewed in the frame of reference of the nozzle (Mach number>1.0).

The main passage 106 only reaches a choked flow condition at the throat 122 if the pressure and mass flow rate is sufficient to reach sonic speeds, otherwise supersonic flow is not achieved and the main passage will act as a venturi tube. In order to achieve supersonic flow, the entry pressure to the nozzle reactor 100 should be significantly above ambient pressure.

The pressure of the fluid at the exit of the divergent section 124 of the main passage 106 can be low, but should not be too low. The exit pressure can be significantly below ambient pressure since pressure cannot travel upstream through the supersonic flow. However, if the pressure is too far below ambient, then the flow will cease to be supersonic or the flow will separate within the divergent section 124 of the main passage 106 forming an unstable jet that “flops” around and damages the main passage 106. In one embodiment, the ambient pressure is no higher than approximately 2-3 times the pressure in the supersonic gas at the exit.

The supersonic reacting fluid collides and mixes with the feed material in the nozzle reactor 100 to produce the desired reaction. The high speeds involved and the resulting collision produces a significant amount of kinetic energy that helps facilitate the desired reaction. The reacting fluid and/or the feed material may also be pre-heated to provide additional thermal energy to react the materials.

The nozzle reactor 100 may be configured to accelerate the reacting fluid to at least approximately Mach 1, at least approximately Mach 1.5, or, desirably, at least approximately Mach 2. The nozzle reactor may also be configured to accelerate the reacting fluid to approximately Mach 1 to approximately Mach 7, approximately Mach 1.5 to approximately Mach 6, or, desirably, approximately Mach 2 to approximately Mach 5.

As shown in FIG. 5, the main passage 106 has a circular cross-section and opposing converging side walls 126, 128. The side walls 126, 128 curve inwardly toward the central axis of the main passage 106. The side walls 126, 128 form the convergent section 120 of the main passage 106 and accelerate the reacting fluid as described above.

The main passage 106 also includes opposing diverging side walls 130, 132. The side walls 130, 132 curve outwardly (when viewed in the direction of flow) away from the central axis of the main passage 106. The side walls 130, 132 form the divergent section 124 of the main passage 106 that allows the sonic fluid to expand and reach supersonic velocities.

The side walls 126, 128, 130, 132 of the main passage 106 provide uniform axial acceleration of the reacting fluid with minimal radial acceleration. The side walls 126, 128, 130, 132 may also have a smooth surface or finish with an absence of sharp edges that may disrupt the flow. The configuration of the side walls 126, 128, 130, 132 renders the main passage 106 substantially isentropic.

The feed passage 108 extends from the exterior of the body portion 104 to an annular chamber 134 formed by head and body portions 102, 104. The portions 102, 104 each have an opposing cavity so that when they are coupled together the cavities combine to form the annular chamber 134. A seal 136 is positioned along the outer circumference of the annular chamber 134 to prevent the feed material from leaking through the space between the head and body portions 102, 104.

It should be appreciated that the head and body portions 102, 104 may be coupled together in any suitable manner. Regardless of the method or devices used, the head and body portions 102, 104 should be coupled together in a way that prevents the feed material from leaking and withstands the forces generated in the interior. In one embodiment, the portions 102, 104 are coupled together using bolts that extend through holes in the outer flanges of the portions 102, 104.

The nozzle reactor 100 includes a distributor 140 positioned between the head and body portions 102, 104. The distributor 140 prevents the feed material from flowing directly from the opening 141 of the feed passage 108 to the main passage 106. Instead, the distributor 140 annularly and uniformly distributes the feed material into contact with the reacting fluid flowing in the main passage 106.

As shown in FIG. 7, the distributor 140 includes an outer circular wall 148 that extends between the head and body portions 102, 104 and forms the inner boundary of the annular chamber 134. A seal or gasket may be provided at the interface between the distributor 140 and the head and body portions 102, 104 to prevent feed material from leaking around the edges.

The distributor 140 includes a plurality of holes 144 that extend through the outer wall 148 and into an interior chamber 146. The holes 144 are evenly spaced around the outside of the distributor 140 to provide even flow into the interior chamber 146. The interior chamber 146 is where the main passage 106 and the feed passage 108 meet and the feed material comes into contact with the supersonic reacting fluid.

The distributor 140 is thus configured to inject the feed material at about a 90° angle to the axis of travel of the reacting fluid in the main passage 106 around the entire circumference of the reacting fluid. The feed material thus forms an annulus of flow that extends toward the main passage 106. The number and size of the holes 144 are selected to provide a pressure drop across the distributor 140 that ensures that the flow through each hole 144 is approximately the same. In one embodiment, the pressure drop across the distributor is at least approximately 2000 pascals, at least approximately 3000 pascals, or at least approximately 5000 pascals.

The distributor 140 includes a wear ring 150 positioned immediately adjacent to and downstream of the location where the feed passage 108 meets the main passage 106. The collision of the reacting fluid and the feed material causes a lot of wear in this area. The wear ring is a physically separate component that is capable of being periodically removed and replaced.

As shown in FIG. 7, the distributor 140 includes an annular recess 152 that is sized to receive and support the wear ring 150. The wear ring 150 is coupled to the distributor 140 to prevent it from moving during operation. The wear ring 150 may be coupled to the distributor in any suitable manner. For example, the wear ring 150 may be welded or bolted to the distributor 140. If the wear ring 150 is welded to the distributor 140, as shown in FIG. 6, the wear ring 150 can be removed by grinding the weld off. In some embodiments, the weld or bolt need not protrude upward into the interior chamber 146 to a significant degree.

The wear ring 150 can be removed by separating the head portion 102 from the body portion 104. With the head portion 102 removed, the distributor 140 and/or the wear ring 150 are readily accessible. The user can remove and/or replace the wear ring 150 or the entire distributor 140, if necessary.

As shown in FIGS. 4 and 5, the main passage 106 expands after passing through the wear ring 150. This can be referred to as expansion area 160 (also referred to herein as an expansion chamber). The expansion area 160 is formed largely by the distributor 140, but can also be formed by the body portion 104.

Following the expansion area 160, the main passage 106 includes a second region having a converging-diverging shape. The second region is in the body portion 104 of the nozzle reactor 100. In this region, the main passage includes a convergent section 170 (also referred to herein as a contraction section), a throat 172, and a divergent section 174 (also referred to herein as an expansion section). The converging-diverging shape of the second region differs from that of the first region in that it is much larger. In one embodiment, the throat 172 is at least 2-5 times as large as the throat 122.

The second region provides additional mixing and residence time to react the reacting fluid and the feed material. The main passage 106 is configured to allow a portion of the reaction mixture to flow backward from the exit opening 112 along the outer wall 176 to the expansion area 160. The backflow then mixes with the stream of material exiting the distributor 140. This mixing action also helps drive the reaction to completion.

The dimensions of the nozzle reactor 100 can vary based on the amount of material that is fed through it. For example, at a flow rate of approximately 590 kg/hr, the distributor 140 can include sixteen holes 144 that are 3 mm in diameter. The dimensions of the various components of the nozzle reactor shown in FIGS. 4 and 5 are not limited, and may generally be adjusted based on the amount of feed flow rate if desired. Table 1 provides exemplary dimensions for the various components of the nozzle reactor 100 based on a hydrocarbon feed input measured in barrels per day (BPD).

TABLE 1
Exemplary nozzle reactor specifications
	Feed Input (BPD)
Nozzle Reactor Component (mm)	5,000	10,000	20,000
Main passage, first region, entry opening	254	359	508
diameter
Main passage, first region, throat diameter	75	106	150
Main passage, first region, exit opening	101	143	202
diameter
Main passage, first region, length	1129	1290	1612
Wear ring internal diameter	414	585	828
Main passage, second region, entry opening	308	436	616
diameter
Main passage, second region, throat diameter	475	672	950
Main passage, second region, exit opening	949	1336	1898
diameter
Nozzle reactor, body portion, outside diameter	1300	1830	2600
Nozzle reactor, overall length	7000	8000	10000

It should be appreciated that the nozzle reactor 100 can be configured in a variety of ways that are different than the specific design shown in the Figures. For example, the location of the openings 110, 112, 114, 116 may be placed in any of a number of different locations. Also, the nozzle reactor 100 may be made as an integral unit instead of comprising two or more portions 102, 104. Numerous other changes may be made to the nozzle reactor 100.

Turning to FIGS. 8 and 9, another embodiment of a nozzle reactor 200 is shown. This embodiment is similar in many ways to the nozzle reactor 100. Similar components are designated using the same reference number used to illustrate the nozzle reactor 100. The previous discussion of these components applies equally to the similar or same components includes as part of the nozzle reactor 200.

The nozzle reactor 200 differs a few ways from the nozzle reactor 100. The nozzle reactor 200 includes a distributor 240 that is formed as an integral part of the body portion 204. However, the wear ring 150 is still a physically separate component that can be removed and replaced. Also, the wear ring 150 depicted in FIG. 9 is coupled to the distributor 240 using bolts instead of by welding. It should be noted that the bolts are recessed in the top surface of the wear ring 150 to prevent them from interfering with the flow of the feed material.

In FIGS. 8 and 9, the head portion 102 and the body portion 104 are coupled together with a clamp 280. The seal, which can be metal or plastic, resembles a “T” shaped cross-section. The leg 282 of the “T” forms a rib that is held by the opposing faces of the head and body portions 102, 104. The two arms or lips 284 form seals that create an area of sealing surface with the inner surfaces 276 of the portions 102, 104. Internal pressure works to reinforce the seal.

The clamp 280 fits over outer flanges 286 of the head and body portions 102, 104. As the portions 102, 104 are drawn together by the clamp, the seal lips deflect against the inner surfaces 276 of the portions 102, 104. This deflection elastically loads the lips 284 against the inner surfaces 276 forming a self-energized seal. In one embodiment, the clamp is made by Grayloc Products, located in Houston, Tex.

When a nozzle reactor as described above and/or in one of the aforementioned documents is used, the desalted bitumen-containing solvent stream leaving the outlet of the desalter can be injected into the nozzle reactor via a feed material inlet included in the nozzle reactor. The outlet of the desalter can be in fluid communication with the feed material inlet of the nozzle reactor in order to allow for transportation of the desalted bitumen-containing solvent stream from the desalter to the nozzle reactor. Once injected into the nozzle reactor via the feed material inlet, the desalted bitumen-containing solvent stream interacts with the cracking material also injected into the nozzle reactor in order to crack and upgrade the bitumen component of the bitumen-containing solvent stream. Additional details of the nozzle reactor upgrading process are set forth in the above-mentioned nozzle reactor Patents and Applications.

FIG. 3 illustrates a system 300 that can be used in order to carry out the methods described above. The system 300 includes a mixing vessel 310, a desalter 320, and a nozzle reactor 330. In operation, a bitumen-containing solvent stream 311 is passed into the mixing vessel 310. Water stream 312 is also passed into the mixing vessel 310 so that the water stream 312 and the bitumen-containing solvent stream mix. A mixture 313 of water and bitumen-containing solvent leaves the mixing vessel 310 and is passed into the desalter. The desalter works to remove solid particles from the mixture 313 as described in greater detail above, and ultimately produces a desalted bitumen-containing solvent stream 321. The desalted bitumen-containing solvent stream 321 is then injected into a nozzle reactor 330. A cracking material 331 is injected into the nozzle reactor at a direction perpendicular to the desalted bitumen-containing solvent stream 321 and can be accelerated to supersonic speed. The cracking material 331 and the desalted bitumen-containing solvent stream 321 interact inside of the nozzle reactor 330 in order to crack and upgrade the bitumen component of the desalted bitumen-containing solvent stream 321. Cracked bitumen (i.e., hydrocarbons that are lighter than the original bitumen) 332 exits the nozzle reactor 330.

The above described processes and methods can be carried out one or more times in order to remove a sufficient amount of non-bitumen solid particles from the bitumen-containing solvent. For example, a series of desalters can be provided wherein the bitumen-containing solvent is moved through each desalter in a series in order to remove sufficient amounts of non-bitumen solid particles. The bitumen-containing solvent can also be run through the same desalter numerous times for achieve a similar result. In some embodiments, a 90% desalting efficiency is desirable and can be achieved by using multiple desalting stages.

In some embodiments, the above described processes and systems are utilized in order to provide a bitumen-containing solvent that has less than 0.5% BS&W (basic sediments and water). Bitumen-containing solvent having a BS&W level below 0.5% can be suitable for pipelining and other downstream processing. Another measure of solid particles in bitumen-containing solvent is PTB or pounds per 1000 bbls of oil or equivalent sodium chloride in pounds per 1000 bbls oil. In some embodiments, obtaining a PTB below 20 is important for providing bitumen-containing solvent suitable for pipelining and downstream processing.

Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, etc. used in the specification are understood as modified in all instances by the term “approximately.” At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims that is modified by the term “approximately” should at least be construed in light of the number of recited significant digits and by applying ordinary rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass and provide support for claims that recite any and all subranges or any and all individual values subsumed therein. For example, a stated range of 1 to 10 should be considered to include and provide support for claims that recite any and all subranges or individual values that are between and/or inclusive of the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).

Claims

1. A method of removing material from bitumen-containing solvent, the material removing method comprising the steps of:

(i) providing a bitumen-containing solvent stream;

(ii) mixing the bitumen-containing solvent stream and a water stream;

(iii) introducing the mixture of the bitumen-containing solvent stream and the water stream in a desalter to remove solid particles from the mixture;

(iv) removing a desalted bitumen-containing solvent stream from the desalter; and

(iv) subjecting the desalted bitumen-containing solvent stream to downstream processing.

2. The material removing method as recited in claim 1, wherein the bitumen-containing solvent stream provided in step i) comprises from 0 to 35% solvent and from 100 to 65% bitumen.

3. The material removing method as recited in claim 2, wherein the solvent component of the bitumen-containing solvent stream comprises an aromatic solvent, a paraffinic solvent, or a polar solvent.

4. The material removing method as recited in claim 1, wherein the bitumen-containing solvent stream comprises inorganic salts.

5. The material removing method as recited in claim 1, wherein prior to processing the mixture in the desalter, the mixture is heated to a temperature in the range of from 80 to 120 ° C.

6. The material removing method as recited in claim 1, wherein prior to mixing the bitumen-containing solvent stream and the water stream, the bitumen-containing solvent stream is heated to a temperature in the range of from 100 to 140° C.

7. The material removing method as recited in claim 1, wherein the mixture includes from 0 to 35% bitumen-containing solvent and from 1 to 25% water.

8. The material removing method as recited in claim 1, further comprising adding an emulsion breaker to the mixture.

9. The material removing method as recited in claim 8, wherein the emulsion breaker comprises amines, amyl resins, butyl resins, and mixtures thereof.

10. The material removing method as recited in claim 1, wherein the bitumen-containing solvent is obtained from a SAGD process.

11. The material removing method as recited in claim 1, wherein the bitumen-containing solvent is obtained from a double solvent extraction process.

12. The material removing method as recited in claim 1, wherein the bitumen-containing solvent is obtained from an in-situ extraction process.

13. The material removing method as recited in claim 1, wherein the bitumen-containing solvent is obtained from a single solvent extraction process.

14. The material removing method as recited in claim 1, wherein the downstream processing comprises distillation of the desalted bitumen-containing solvent stream.

15. The material removing method as recited in claim 1, wherein the downstream processing comprises cracking of the bitumen content of the desalted bitumen-containing solvent stream in a nozzle reactor.

16. A method of removing material from bitumen-containing solvent, the material removing method comprising the steps of:

(i) providing a bitumen-containing solvent stream;

(ii) mixing the bitumen-containing solvent stream and a water stream;

(iii) introducing the mixture of the bitumen-containing solvent stream and the water stream in a desalter to remove solid particles from the mixture;

(iv) removing a desalted bitumen-containing solvent stream from the desalter; and

(iv) upgrading the desalted bitumen-containing solvent stream in a nozzle reactor.

17. The material removing method as recited in claim 16, wherein the nozzle reactor comprises:

a reactor body having a reactor body passage with an injection end and an ejection end;

a first material injector having a first material injection passage and being mounted in the nozzle reactor in material injecting communication with the injection end of the reactor body passage, the first material injection passage having (a) an enlarged volume injection section, an enlarged volume ejection section, and a reduced volume mid-section intermediate the enlarged volume injection section and enlarged volume ejection section, (b) a material injection end in material injecting communication with the combustion chamber, and (c) a material ejection end in material injecting communication with the reactor body passage; and

a second material feed port penetrating the reactor body and being (a) adjacent to the material ejection end of the first material injection passage and (b) transverse to a first material injection passage axis extending from the material injection end to the material ejection end in the first material injection passage in the first material injector;

18. A system for removing material from bitumen-containing solvent, the material removing system comprising:

a desalter having a bitumen-containing solvent stream inlet and a desalted bitumen-containing solvent stream outlet; and

a nozzle reactor having a feed material inlet, wherein the feed material inlet is in fluid communication with the desalted bitumen-containing solvent stream outlet of the desalter.

19. The material removing system as recited in claim 18, wherein the structure of the nozzle reactor comprises:

a reactor body having a reactor body passage with an injection end and an ejection end;

a first material injector having a first material injection passage and being mounted in the nozzle reactor in material injecting communication with the injection end of the reactor body passage, the first material injection passage having (a) an enlarged volume injection section, an enlarged volume ejection section, and a reduced volume mid-section intermediate the enlarged volume injection section and enlarged volume ejection section, (b) a material injection end in material injecting communication with the combustion chamber, and (c) a material ejection end in material injecting communication with the reactor body passage; and

a second material feed port penetrating the reactor body and being (a) adjacent to the material ejection end of the first material injection passage and (b) transverse to a first material injection passage axis extending from the material injection end to the material ejection end in the first material injection passage in the first material injector;

20. The material removing system as recited in claim 18, further comprising:

a mixing vessel having a water inlet, a bitumen-containing solvent stream inlet, and a bitumen-containing solvent stream outlet, wherein the bitumen-containing solvent stream outlet of the mixing vessel is in fluid communication with the bitumen-containing solvent stream inlet of the desalter.